Zero Flex Flyer Tube size?

(x10wakerider) · (x10wakerider) **Join Date: Jan 2004** 03-04-2004, 9:30 AM

Iam buying a lightbar off the internet and I have to know the size of the tube for the mounting brackets. Let me know
Thanks

austinb 03-04-2004, 9:56 AM

I have a '02 X9 with a Zero Flex Tower. I was told by the dealer it is 1-7/8".

(leetudor) · (leetudor) **Join Date: Oct 2001** 03-04-2004, 6:19 PM

Depends on the year.

(ktm250) · (ktm250) **Join Date: Jan 2003** 03-05-2004, 6:12 AM

All zero flex towers are 1-7/8"...except '03 and newer X-Star and X-80.

(migitty) · (migitty) **Join Date: Aug 2001** 03-05-2004, 9:48 AM

I have a '00 and it's a 1.9, not 1-7/8. I know this for a fact. My dealer also told me it was 1 7/8 but they were wrong. You can always buy a feeler guage for around $6 if you don't know for sure.

tommyadrian5 03-05-2004, 10:38 AM

1 7/8" is 1.875", which is .025, or a quarter of a tenth of an inch smaller than 1.9 inches, it is 1 7/8"

(ktm250) · (ktm250) **Join Date: Jan 2003** 03-05-2004, 11:03 AM

Well, not wanting to give out incorrect information I just measured 4 towers, model years 1999, 2000, 2001 and 2004 (installed on X-Star and X2). EVERY single one of them measures 1.875 to 1.900 (5 random measurements per tower). Now to put that into perspective the difference between the published specs of 1-7/8" and a measured 1.900" is .025"...put in everyday terms that is the thickness of 5 sheets of copier paper (yes, I measured them). Before anyone asks I used a Mitutoyo 6” dial caliper that was certified accurate last year (10/03).

The difference in tubing diameter can be traced to the tubing itself…this isn’t mil-spec stuff here, combine that with a product that has been clear anodized, bent and welded…and you get some variance that should easily fall within the specs of any aftermarket supplier.

(x10wakerider) · (x10wakerider) **Join Date: Jan 2004** 03-05-2004, 12:00 PM

Thanks, Guys!

tattoobling 03-05-2004, 1:25 PM

Blake,

Are you sure you got the whole picture?